Woven carbon fiber reinforced steel matrix composite

Abstract

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than steel, and are expected to have appreciable strength. Methods for forming composite steel composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein.

What is claimed is: 
     
       1. A composite material comprising:
 a continuous matrix of sintered metal nanoparticles selected from the group consisting of steel and titanium; and 
 at least one reinforcing carbon fiber that is at least partially encapsulated within the continuous matrix. 
 
     
     
       2. The composite material as recited in  claim 1 , wherein the at least one reinforcing carbon fiber is fully encapsulated within the continuous matrix. 
     
     
       3. The composite material as recited in  claim 1 , wherein the at least one reinforcing carbon fiber is partially encapsulated within the continuous matrix. 
     
     
       4. The composite material as recited in  claim 1 , wherein the at least one reinforcing carbon fiber is a plurality of reinforcing carbon fibers in the form of a plurality of spatially separated layers of reinforcing carbon fiber. 
     
     
       5. The composite material as recited in  claim 1 , having density less than 7 g/cm 3 . 
     
     
       6. The composite material as recited in  claim 1 , having density less than 6 g/cm 3 . 
     
     
       7. The composite material as recited in  claim 1 , having density less than 5 g/cm 3 . 
     
     
       8. The composite material as recited in  claim 1 , wherein the continuous matrix comprises an alloy of iron, carbon, and at least one element selected from a group including: Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si. 
     
     
       9. A composite material comprising:
 at least one reinforcing fiber structure comprising a combination of carbon fiber and ceramic fiber; and 
 a continuous steel matrix, of sintered steel nanoparticles, disposed around the at least one reinforcing fiber structure. 
 
     
     
       10. The composite material as recited in  claim 9 , having density less than 7 g/cm 3 . 
     
     
       11. The composite material as recited in  claim 9 , having density less than 6 g/cm 3 . 
     
     
       12. The composite material as recited in  claim 9 , having density less than 5 g/cm 3 . 
     
     
       13. The composite material as recited in  claim 9 , wherein the continuous steel matrix comprises an alloy of iron, carbon, and at least one element selected from a group including: Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si.